Microtextured liquid transport element for aerosol delivery device

ABSTRACT

The present disclosure relates to aerosol delivery devices. The aerosol delivery devices may include a reservoir containing a liquid aerosol precursor composition and an atomizer including an electrical resistance heating element and a nonfibrous liquid transport element having a microtextured surface adapted for surface wicking of the liquid aerosol precursor composition across the microtextured surface, the microtextured surface of the liquid transport element being in fluid communication with the reservoir and in fluid communication with the electric resistance heating element.

BACKGROUND Field of the Disclosure

The present disclosure relates to aerosol delivery devices such aselectronic cigarettes, and more particularly to aerosol delivery devicesincluding an atomizer. The atomizer may be configured to heat an aerosolprecursor composition, which may be made or derived from tobacco orotherwise incorporate tobacco, to form an inhalable substance for humanconsumption.

Description of Related Art

Many devices have been proposed through the years as improvements upon,or alternatives to, smoking products that require combusting tobacco foruse. Many of those devices purportedly have been designed to provide thesensations associated with cigarette, cigar, or pipe smoking, butwithout delivering considerable quantities of incomplete combustion andpyrolysis products that result from the burning of tobacco. To this end,there have been proposed numerous alternative smoking products, flavorgenerators, and medicinal inhalers that utilize electrical energy tovaporize or heat a volatile material, or attempt to provide thesensations of cigarette, cigar, or pipe smoking without burning tobaccoto a significant degree. See, for example, the various alternativesmoking articles, aerosol delivery devices and heat generating sourcesset forth in the background art described in U.S. Pat. No. 8,881,737 toCollett et al., U.S. Pat. App. Pub. No. 2013/0255702 to Griffith Jr. etal., U.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., U.S. Pat.App. Pub. No. 2014/0096781 to Sears et al., U.S. Pat. App. Pub. No.2014/0096782 to Ampolini et al., and U.S. Pat. App. Pub. No.2015/0059780 to Davis et al., which are incorporated herein by referencein their entireties. See also, for example, the various embodiments ofproducts and heating configurations described in the background sectionsof U.S. Pat. No. 5,388,594 to Counts et al. and U.S. Pat. No. 8,079,371to Robinson et al., which are incorporated by reference in theirentireties.

Many electronic cigarette products comprise an atomizer with a“wick/coil” design, which includes an electrical resistance heater wirewrapped around a fibrous wicking material. Such a design has severalpotential drawbacks, including heating inefficiency, non-homogeneouswicking of liquid components, non-uniform heating or vaporization ofliquid components, the presence of heat sinks, and non-optimalaerodynamics. In addition, the wick/coil design may lead to pyrolysisand/or deposition of char at the wick and coil interface. Some of thesepotential drawbacks can cause a negative sensory impact over time thatmay limit how long the device can be operated before the atomizer needsreplacement.

There remains a need in the art for new atomizer configurations that canimprove upon one or more characteristics of an aerosol delivery device,such as uniformity of heating or vaporization, heating efficiency,reduction of charring/pyrolysis, and the like.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to an atomizer for aerosol deliverydevices configured to produce aerosol and which aerosol deliverydevices, in some embodiments, may be referred to as electroniccigarettes. In one aspect, an aerosol delivery device is provided thatincludes a reservoir containing a liquid aerosol precursor compositionand an atomizer comprising an electrical resistance heating element anda nonfibrous liquid transport element (which is optionally plate-shaped)having a microtextured surface adapted for surface wicking of the liquidaerosol precursor composition across the microtextured surface, themicrotextured surface of the liquid transport element being in fluidcommunication with the reservoir and in fluid communication with theelectric resistance heating element. Use of a microtextured solidsurface enables surface wicking of the aerosol precursor compositionfrom a first portion of the liquid transport element into a heating zoneproximal to the heating element.

In certain embodiments, the electrical resistance heating element is afilm (e.g., a conductive ink) patterned on the microtextured surface ofthe nonfibrous liquid transport element. The film patterned on themicrotextured surface can include one or more straight or curvilinearelements extending from a first end to a second end. A protective layeroverlying the electrical resistance heating element can also be includedsuch that liquid aerosol precursor composition transported across themicrotextured surface does not directly contact the electricalresistance heating element.

In certain embodiments, the film patterned on the microtextured surfaceextends from a first end to a second end, and the device furthercomprises an aperture in the nonfibrous liquid transport elementproximal to each of the first end and the second end, and furthercomprises a positive electric terminal engaged with a first end of thefilm through an aperture and a negative electric terminal engaged with asecond end of the film through an aperture such that an electric currentcan be passed from terminal to terminal.

In certain embodiments, the device also includes a secondary liquidtransport element (e.g., a fibrous material or ceramic material)interposed in a flow path between the reservoir and the nonfibrousliquid transport element and wherein the secondary liquid transportelement is in fluid communication with the reservoir and in fluidcommunication with at least a portion of the nonfibrous liquid transportelement. In such embodiments, it is possible for the microtexturedsurface of the nonfibrous liquid transport element to comprise a heatingzone that includes the electrical resistance heating element and asecond zone in spaced relation from the electrical resistance heatingelement, and wherein the secondary liquid transport element is in fluidcommunication with at least a portion of the second zone such that aflow path for the liquid aerosol precursor composition is establishedfrom the secondary liquid transport element to the second zone and fromthe second zone to the heating zone across the microtextured surface.For example, if the nonfibrous liquid transport element is plate-shapedwith a peripheral edge surrounding a central region, the second zone istypically located proximal to the peripheral edge and the heating zonecomprises at least a portion of the central region. Alternatively, thesecondary liquid transport element can be in fluid communication withall or portions of both the second zone and the heating zone.

The secondary liquid transport element can, for example, overlie atleast a portion of the microtextured surface. In certain embodiments,the secondary liquid transport element can overlie substantially all ofthe microtextured surface. In addition, the device can include at leastone aperture through the nonfibrous liquid transport element, wherein atleast a portion of the secondary liquid transport element passes throughthe at least one aperture.

The reservoir and atomizer can be, for example, housed in a cartridgeadapted for attachment to a control body, the control body comprising anelectrical power source configured to provide electrical current flow tothe electrical resistance heating element. In addition, the aerosoldelivery device can further include one or more of (a) an electricalpower source configured to provide electrical current flow to theelectrical resistance heating element; (b) a controller adapted forcontrolling electrical current flow from the electrical power source;and (c) a flow sensor in communication with the controller and adaptedto sense a pressure drop within the aerosol delivery device or a portionthereof.

In one particular embodiment, the invention provides an aerosol deliverydevice, the device comprising: a reservoir containing a liquid aerosolprecursor composition; an atomizer comprising a nonfibrous liquidtransport element having a microtextured surface adapted for surfacewicking of the liquid aerosol precursor composition across themicrotextured surface and an electrical resistance heating element inthe form of a film patterned on the microtextured surface of thenonfibrous liquid transport element, the film having a first end and asecond end, the microtextured surface of the liquid transport elementbeing in fluid communication with the reservoir and in fluidcommunication with the electrical resistance heating element; and anaperture in the nonfibrous liquid transport element proximal to each ofthe first end and the second end, and further comprising a positiveelectric terminal engaged with a first end of the film through anaperture and a negative electric terminal engaged with a second end ofthe film through an aperture such that an electric current can be passedfrom terminal to terminal.

The above-noted device can further include a secondary liquid transportelement interposed in a flow path between the reservoir and thenonfibrous liquid transport element and wherein the secondary liquidtransport element is in fluid communication with the reservoir and influid communication with at least a portion of the nonfibrous liquidtransport element. Still further, the microtextured surface of thenonfibrous liquid transport element can comprise a heating zone thatincludes the electrical resistance heating element and a second zone inspaced relation from the electrical resistance heating element asdescribed above. In addition, the nonfibrous liquid transport elementcan be plate-shaped with a peripheral edge surrounding a central region,and wherein the second zone is typically located proximal to theperipheral edge and the heating zone comprises at least a portion of thecentral region.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates an aerosol delivery device comprising a cartridge anda control body in an assembled configuration according to an exampleembodiment of the present disclosure;

FIG. 2 illustrates the control body of FIG. 1 in an explodedconfiguration according to an example embodiment of the presentdisclosure;

FIG. 3 illustrates the cartridge of FIG. 1 in an exploded configurationaccording to an example embodiment of the present disclosure;

FIG. 4 illustrates a top view of an atomizer according to an exampleembodiment of the present disclosure;

FIG. 5 illustrates a top view of an atomizer according to a furtherexample embodiment of the present disclosure;

FIG. 6 illustrates a top view of an atomizer according to yet anotherexample embodiment of the present disclosure;

FIG. 7 illustrates a side view of an atomizer with a protective layeraccording to an example embodiment of the present disclosure;

FIGS. 8A and 8B illustrate a perspective view and an explodedconfiguration, respectively, of a cartridge according to a furtherexample embodiment of the present disclosure;

FIG. 9 illustrates a perspective view of a cartridge according to yetanother example embodiment of the present disclosure;

FIG. 10 illustrates a cross-sectional view of the cartridge of FIG. 9;and

FIG. 11 illustrates a further cross-sectional view of the atomizerportion of the cartridge of FIG. 9 with the liquid transport elementwith the microtextured surface shown at full size.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

The invention provides an aerosol delivery device that includes areservoir containing a liquid aerosol precursor composition and anatomizer. The atomizer includes an electric resistance heating elementand a nonfibrous liquid transport element having a microtextured surfaceadapted for surface wicking of the liquid aerosol precursor compositionacross the microtextured surface. The microtextured surface is in fluidcommunication with the reservoir and in fluid communication with theelectric resistance heating element, meaning the microtextured surfaceprovides at least a portion of the flow path for the liquid aerosolprecursor composition between the reservoir and the heating element. Asnoted, the liquid transport element is preferably nonfibrous, meaningthe liquid transport element is formed from a solid material having amicrotextured surface rather than a surface formed by a plurality ofbundled fibers.

As notes herein, “microtextured” refers to a surface havingtopographical three-dimensional features at the micro-meter scale (e.g.,a plurality of three-dimensional surface features having an averageheight of less than about 250 microns) that are discontinuous inappearance such that the surface includes multiple concave and convexportions. Such a surface can also be referred to as roughened ormicro-patterned, although the surface features of the microtexturedsurface can be either an ordered array of structures that follow apattern or relatively random in arrangement. In certain embodiments, themicrotextured surface can be quantified using root mean square (RMS)analysis, with exemplary ranges including Sq values of from about 3 toabout 16 microns (e.g., about 4 to about 15 microns including about 4microns, about 5 microns, about 6 microns, about 7 microns, about 8microns, about 9 microns, about 10 microns, about 11 microns, about 12microns, about 13 microns, about 14 microns, and about 15 microns).Certain embodiments have an Sq range of about 3 microns to about 6microns, about 6 microns to about 10 microns, or about 12 microns toabout 15 microns. RMS data can be generated using a Zeiss LSM 800instrument (confocal microscope) and following the ISO 25178 protocol.

The microtextured surface can exhibit a variety of geometries (e.g.,pillars, channels, platelets, cones, divots, etc.). In addition, themicrotextured surface can be substantially constant (e.g., exhibiting asingle, repeating feature of substantially unchanging dimensions) and/orcan exhibit a substantially repeating pattern (e.g., a plurality offeatures differing in one or more of size, shape, and spacing, thatdefine an ordered, repeating pattern). However, without departing fromthe invention, the microtextured surface could also exhibit a relativelynon-uniform or irregular plurality of surface protrusions. Themicrotextured surface can be defined at least in part in relation to thesize and/or spacing of the geometric elements forming the microtexture.For example, the geometric elements can have an average height of about1 μm to about 250 μm, about 1.5 μm to about 200 μm, about 2 μm to about100 μm, about 2.5 μm to about 50 μm, or about 3 μm to about 25 μm. Thegeometric elements can have an average spacing of about 0.1 μm to about20 μm, about 0.25 μm to about 15 μm, about 0.5 μm to about 10 μm, orabout 1 μm to about 5 μm.

The microtextured surface is adapted to provide surface wicking,sometimes referred to as “hemi-wicking,” across the surface such that asteady supply of liquid aerosol precursor composition is delivereddirectly into close proximity of the heating element. In certainembodiments, this wicking phenomenon can contribute to improveduniformity of heating or vaporization and improved heating efficiency ascompared to traditional wick/coil atomizer configurations.

Various embodiments of methods may be employed to form the microtexturedsurface of the present disclosure. In one example method, the liquidtransport element is formed in a mold configured to define the surfaceincluding the microtexture. The mold may be etched (e.g., chemical,electrochemical, or laser etched) to define a microtextured surface thatis then transferred to the liquid transport element. However, variousother embodiments of methods for forming the surface may be employed.For example, the microtextured surface can be produced by one or moremethods such as self-assembly of a monolayer, photolithography,machining, lapping (e.g., diamond lapping), plasma spraying,electrospinning, irradiation, template methods, chemical deposition, wetetching, dry etching, and blasting (e.g., with sand, sodium bicarbonate,or dry ice, optionally followed by anodizing the blasted surface).Various examples of such methods for producing surfaces including amicro-pattern are described in Artificial Lotus Leaf Structures Made byBlasting with Sodium Bicarbonate by Lee et al., which is incorporatedherein by reference in its entirety.

The electric resistance heating element can comprise a metal or likematerial as otherwise described herein suitable for providing resistiveheating. Although the heating element can be placed on a separatesubstrate or otherwise spaced apart from the microtextured surface(although still in fluid communication therewith), it is advantageousfor the heating element to be physically combined with the liquidtransport element having the microtextured surface, such as by variousmeans that include etching techniques, printing techniques, or adheringtechniques. For example, a metal ribbon can be laminated or otherwiseaffixed to the liquid transport element.

Advantageously, the electric resistance heating element is in the formof a film patterned on the microtextured surface of the liquid transportelement. The thickness of the electrically conductive film layer canvary and can be, for example, about 1,000 μm or less, about 500 μm orless, about 200 μm or less, about 100 μm or less, about 50 μm or less,about 10 μm or less, or about 5 μm or less. In other embodiments, theelectrically conductive film layer can have a thickness of about 0.1 μmto about 500 μm, about 0.5 μm to about 200 μm, about 1 μm to about 100μm, or about 2 μm to about 50 μm.

Where a conductive film is used, the electrically conductive materialused in the heating element can comprise essentially any material thatis both electrically conductive and suitable for thin film formation.For example, the electrically conductive material can be selected fromthe group consisting of elemental metals, metal alloys, silicon(including single crystal silicon and poly-silicon), ceramics, carbon,carbides, nitrides, and combinations thereof. In more specificembodiments, the electrically conductive material can be formed ofplatinum, gold, silver, copper, aluminum, tungsten, zinc, palladium,nickel, titanium, nichrome, silicon carbide, poly-silicon, singlecrystal silicon, titanium nitride, and the like. In particularembodiments, elemental metals, such as platinum, can be particularlybeneficial due to exhibiting good oxidation resistance and long-termstability.

In certain embodiments, an electrically conductive ink can be printed onthe surface of the heating element as a patterned film. A heatingelement formed from an electrically conductive ink can be configured ina variety of patterns of varying complexity. Exemplary conductive inksinclude graphene inks and inks containing various metals, such as inksincluding silver, gold, palladium, platinum, and alloys or othercombinations thereof (e.g., silver-palladium or silver-platinum inks).

In aspects implementing the imprinting of a conductive ink (e.g., asilver-containing ink), the ink may be applied using a variety ofprinting processes such as, for instance, gravure printing, flexographicprinting, off-set printing, screen printing, ink-jet printing, or otherappropriate printing method, in order to provide varying thicknesses,patterns, surface coverage, and composition gradients. Printing of anelectrically conductive ink on the fluid transport element can improvemanufacturing in that fewer materials and/or fewer processing steps maybe required, and high throughput printing techniques can be utilized torapidly prepare the heating element. In addition, it has been discoveredthat printing a thin film heating element on the microtextured surfacecan enhance durability of the heating element by reducing film crackingand other discontinuations that can result either during drying of theink or when applying a current to the ink. Still further, in certainembodiments, the use of a microtextured surface in combination with athin film heating element applied thereto is believed to provide reducedcharring/pyrolysis as compared to traditional wick/coil atomizerarrangements.

The liquid transport element with the microtextured surface can beformed of a substrate material that is preferably thermally andmechanically stable under the conditions of use. For example, the liquidtransport element may be formed of a material that is temperature stableat a temperature of about 100° C. or greater, about 150° C. or greater,about 200° C. or greater, about 300° C. or greater, about 400° C. orgreater, or about 500° C. or greater. In other embodiments, the liquidtransport element can be temperature stable in a temperature range ofabout 100° C. to about 750° C., about 125° C. to about to about 650° C.,or about 150° C. to about 500° C. In some embodiments, the liquidtransport element can be formed of a ceramic material, particularly asilicon-based material, such as a silicon nitride or silicon dioxidematerial. Other materials, however, such as glass or quartz can be used.Certain thermoplastic materials, such as cyclic olefin copolymers (COC),also can be used.

In some embodiments, the liquid transport element can have a relativelysmall thickness—e.g., about 1 mm to about 20 mm, about 1.5 mm to about15 mm, or about 2 mm to about 10 mm. In some embodiments, the liquidtransport element can have a surface area of about 0.5 cm² to about 50cm², about 1 cm² to about 45 cm², about 2 cm² to about 40 cm², or about3 cm² to about 30 cm². The liquid transport element can be characterizedin relation to its further dimensions as well. Specifically, the liquidtransport element can have a length and a width that are independentlyup to about 25 mm, up to about 20 mm, up to about 15 mm, or up to about10 mm. In other embodiments, the length and width of the liquidtransport element independently can be about 0.25 mm to about 25 mm,about 0.5 mm to about 15 mm, about 0.6 mm to about 10 mm, about 0.7 mmto about 7.5 mm, or about 0.75 mm to about 5 mm.

In certain embodiments, the liquid transport element can beplate-shaped, meaning a shape that is substantially flat and has alength and a width that are both greater than the thickness. Such aliquid transport element may be substantially square or rectangular;however, other shapes (e.g., round, oval, triangular, or othermulti-sided shapes) could also be used. Additional geometries for theliquid transport element could also be used, such as cylindrical shapes.

The present disclosure provides descriptions of aerosol deliverydevices. The aerosol delivery devices may use electrical energy to heata material (preferably without combusting the material to anysignificant degree) to form an inhalable substance; such articles mostpreferably being sufficiently compact to be considered “hand-held”devices. An aerosol delivery device may provide some or all of thesensations (e.g., inhalation and exhalation rituals, types of tastes orflavors, organoleptic effects, physical feel, use rituals, visual cuessuch as those provided by visible aerosol, and the like) of smoking acigarette, cigar, or pipe, without any substantial degree of combustionof any component of that article or device. The aerosol delivery devicemay not produce smoke in the sense of the aerosol resulting fromby-products of combustion or pyrolysis of tobacco, but rather, that thearticle or device most preferably yields vapors (including vapors withinaerosols that can be considered to be visible aerosols that might beconsidered to be described as smoke-like) resulting from volatilizationor vaporization of certain components of the article or device, althoughin other embodiments the aerosol may not be visible. In highly preferredembodiments, aerosol delivery devices may incorporate tobacco and/orcomponents derived from tobacco. As such, the aerosol delivery devicecan be characterized in certain embodiments as an electronic smokingarticle such as an electronic cigarette or “e-cigarette.”

While the systems are generally described herein in terms of embodimentsassociated with aerosol delivery devices such as so-called“e-cigarettes,” it should be understood that the mechanisms, components,features, and methods may be embodied in many different forms andassociated with a variety of articles. For example, the descriptionprovided herein may be employed in conjunction with embodiments oftraditional smoking articles (e.g., cigarettes, cigars, pipes, etc.) orheat-not-burn smoking articles. Accordingly, it should be understoodthat the description of the mechanisms, components, features, andmethods disclosed herein are discussed in terms of embodiments relatingto aerosol delivery devices by way of example only, and may be embodiedand used in various other products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

The invention will now be described by reference to various figures.Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer shell or body. The overalldesign of the outer shell or body can vary, and the format orconfiguration of the outer body that can define the overall size andshape of the aerosol delivery device can vary. Typically, an elongatedbody resembling the shape of a cigarette or cigar can be a formed from asingle, unitary shell; or the elongated body can be formed of two ormore separable pieces. For example, an aerosol delivery device cancomprise an elongated shell or body that can be substantially tubular inshape and, as such, resemble the shape of a conventional cigarette orcigar. However, various other shapes and configurations may be employedin other embodiments (e.g., rectangular or fob-shaped).

In one embodiment, all of the components of the aerosol delivery deviceare contained within one outer body or shell. Alternatively, an aerosoldelivery device can comprise two or more shells that are joined and areseparable. For example, an aerosol delivery device can possess at oneend a control body comprising a shell containing one or more reusablecomponents (e.g., a rechargeable battery and various electronics forcontrolling the operation of that article), and at the other end andremovably attached thereto a shell containing a disposable portion(e.g., a disposable flavor-containing cartridge). More specific formats,configurations and arrangements of components within the single shelltype of unit or within a multi-piece separable shell type of unit willbe evident in light of the further disclosure provided herein.Additionally, various aerosol delivery device designs and componentarrangements can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e-juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific embodiments, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement can be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof, whereinsuch terms are also interchangeably used herein except where otherwisespecified.

As noted above, the aerosol delivery device may incorporate a battery orother electrical power source (e.g., a capacitor) to provide currentflow sufficient to provide various functionalities to the aerosoldelivery device, such as powering of a heater, powering of controlsystems, powering of indicators, and the like. The power source can takeon various embodiments. Preferably, the power source is able to deliversufficient power to rapidly heat the heating element to provide foraerosol formation and power the aerosol delivery device through use fora desired duration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices. Further, the arrangementof the components within the aerosol delivery device can also beappreciated upon consideration of the commercially available electronicaerosol delivery devices. Examples of commercially available products,for which the components thereof, methods of operation thereof,materials included therein, and/or other attributes thereof may beincluded in the devices of the present disclosure have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byLorillard Technologies, Inc.; COHITA™, COLIBRI™, ELITE CLASSIC™,MAGNUM™, PHANTOM™ and SENSE™ by Epuffer® International Inc.; DUOPRO™,STORM™ and VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by EgarAustralia; eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd;EONSMOKE® by Eonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® byGreen Smoke Inc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™,HENDU™, JET™, MAXXQ™, PINK™ and PITBULL™ by Smoke Stik®; HEATBAR™ byPhilip Morris International, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7;LOGIC™ and THE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.;METRO® by Nicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SSChoice LLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPPE-MYSTICK™ by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products,LLC; RUYAN® by Ruyan Group (Holdings) Ltd.; SF® by Smoker FriendlyInternational, LLC; GREEN SMART SMOKER® by The Smart Smoking ElectronicCigarette Company Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; AVIGO, VUSE, VUSE CONNECT, VUSE FOB, VUSEHYBRID, ALTO, ALTO+, MODO, CIRO, FOX+FOG, AND SOLO+ by R. J. ReynoldsVapor Company; MISTIC MENTHOL by Mistic Ecigs; and VYPE by CN CreativeLtd. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; SOUTH BEACHSMOKE™.

Additional manufacturers, designers, and/or assignees of components andrelated technologies that may be employed in the aerosol delivery deviceof the present disclosure include Shenzhen Jieshibo Technology ofShenzhen, China; Shenzhen First Union Technology of Shenzhen City,China; Safe Cig of Los Angeles, Calif.; Janty Asia Company of thePhilippines; Joyetech Changzhou Electronics of Shenzhen, China; SISResources; B2B International Holdings of Dover, Del.; Evolv LLC of OH;Montrade of Bologna, Italy; Shenzhen Bauway Technology of Shenzhen,China; Global Vapor Trademarks Inc. of Pompano Beach, Fla.; Vapor Corp.of Fort Lauderdale, Fla.; Nemtra GMBH of Raschau-Markersbach, Germany,Perrigo L. Co. of Allegan, Mich.; Needs Co., Ltd.; Smokefree Innotec ofLas Vegas, Nev.; McNeil AB of Helsingborg, Sweden; Chong Corp; AlexzaPharmaceuticals of Mountain View, Calif.; BLEC, LLC of Charlotte, N.C.;Gaitrend Sarl of Rohrbach-lès-Bitche, France; FeelLife BioscienceInternational of Shenzhen, China; Vishay Electronic BMGH of Selb,Germany; Shenzhen Smaco Technology Ltd. of Shenzhen, China; VaporSystems International of Boca Raton, Fla.; Exonoid Medical Devices ofIsrael; Shenzhen Nowotech Electronic of Shenzhen, China; MinilogicDevice Corporation of Hong Kong, China; Shenzhen Kontle Electronics ofShenzhen, China, and Fuma International, LLC of Medina, Ohio, 21stCentury Smoke of Beloit, Wis., and Kimree Holdings (HK) Co. Limited ofHong Kong, China.

One example embodiment of an aerosol delivery device 100 is illustratedin FIG. 1. In particular, FIG. 1 illustrates an aerosol delivery device100 including a control body 200 and a cartridge 300. The control body200 and the cartridge 300 can be permanently or detachably aligned in afunctioning relationship. Various mechanisms may connect the cartridge300 to the control body 200 to result in a threaded engagement, apress-fit engagement, an interference fit, a magnetic engagement, or thelike. The aerosol delivery device 100 may be substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome embodiments when the cartridge 300 and the control body 200 are inan assembled configuration. However, as noted above, various otherconfigurations such as rectangular or fob-shaped may be employed inother embodiments. Further, although the aerosol delivery devices aregenerally described herein as resembling the size and shape of atraditional smoking article, in other embodiments differingconfigurations and larger capacity reservoirs, which may be referred toas “tanks,” may be employed.

In specific embodiments, one or both of the cartridge 300 and thecontrol body 200 may be referred to as being disposable or as beingreusable. For example, the control body 200 may have a replaceablebattery or a rechargeable battery and/or capacitor and thus may becombined with any type of recharging technology, including connection toa typical alternating current electrical outlet, connection to a carcharger (i.e., cigarette lighter receptacle), and connection to acomputer, such as through a universal serial bus (USB) cable. Further,in some embodiments the cartridge 300 may comprise a single-usecartridge, as disclosed in U.S. Pat. No. 8,910,639 to Chang et al.,which is incorporated herein by reference in its entirety.

FIG. 2 illustrates an exploded view of the control body 200 of theaerosol delivery device 100 (see, FIG. 1) according to an exampleembodiment of the present disclosure. As illustrated, the control body200 may comprise a coupler 202, an outer body 204, a sealing member 206,an adhesive member 208 (e.g., KAPTON® tape), a flow sensor 210 (e.g., apuff sensor or pressure switch), a control component 212, a spacer 214,an electrical power source 216 (e.g., a capacitor and/or a battery,which may be rechargeable), a circuit board with an indicator 218 (e.g.,a light emitting diode (LED)), a connector circuit 220, and an end cap222. Examples of electrical power sources are described in U.S. Pat.App. Pub. No. 2010/0028766 by Peckerar et al., the disclosure of whichis incorporated herein by reference in its entirety.

With respect to the flow sensor 210, representative current regulatingcomponents and other current controlling components including variousmicrocontrollers, sensors, and switches for aerosol delivery devices aredescribed in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. App. Pub. No. 2014/0270727 to Ampolini et al., whichis incorporated herein by reference in its entirety.

In one embodiment the indicator 218 may comprise one or more lightemitting diodes. The indicator 218 can be in communication with thecontrol component 212 through the connector circuit 220 and beilluminated, for example, during a user drawing on a cartridge coupledto the coupler 202, as detected by the flow sensor 210. The end cap 222may be adapted to make visible the illumination provided thereunder bythe indicator 218. Accordingly, the indicator 218 may be illuminatedduring use of the aerosol delivery device 100 to simulate the lit end ofa smoking article. However, in other embodiments the indicator 218 canbe provided in varying numbers and can take on different shapes and caneven be an opening in the outer body (such as for release of sound whensuch indicators are present).

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and WO 2010/003480 by Flick discloses a fluid flowsensing system indicative of a puff in an aerosol generating system; allof the foregoing disclosures being incorporated herein by reference intheir entireties. Further examples of components related to electronicaerosol delivery articles and disclosing materials or components thatmay be used in the present article include U.S. Pat. No. 4,735,217 toGerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan;U.S. Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231to Thorens et al.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat.Nos. 8,915,254 and 8,925,555 to Monsees et al.; and U.S. Pat. No.9,220,302 to DePiano et al.; U.S. Pat. App. Pub. Nos. 2006/0196518 and2009/0188490 to Hon; U.S. Pat. App. Pub. No. 2010/0024834 to Oglesby etal.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; WO 2010/091593 toHon; and WO 2013/089551 to Foo, each of which is incorporated herein byreference in its entirety. A variety of the materials disclosed by theforegoing documents may be incorporated into the present devices invarious embodiments, and all of the foregoing disclosures areincorporated herein by reference in their entireties.

FIG. 3 illustrates the cartridge 300 of the aerosol delivery device 100(see, FIG. 1) in an exploded configuration. As illustrated, thecartridge 300 may comprise a base 302, a control component terminal 304,an electronic control component 306, a flow director 308, an atomizer310, a reservoir 312 (e.g., a reservoir substrate), an outer body 314, amouthpiece 316, a label 318, and first and second heating terminals 320,321 according to an example embodiment of the present disclosure.

In some embodiments the first and second heating terminals 320, 321 maybe embedded in, or otherwise coupled to, the flow director 308. Forexample, the first and second heating terminals 320, 321 may be insertmolded in the flow director 308. Accordingly, the flow director 308 andthe first and second heating terminals are collectively referred toherein as a flow director assembly 322. Additional description withrespect to the first and second heating terminals 320, 321 and the flowdirector 308 is provided in U.S. Pat. Pub. No. 2015/0335071 to Brinkleyet al., which is incorporated herein by reference in its entirety.

In the embodiment shown in FIG. 3, the atomizer 310 may comprise aliquid transport element 324 with a microtextured surface as describedherein and a heating element 326 as described herein (e.g., a conductiveink applied to the microtextured surface of the liquid transportelement). The liquid transport element 324 can include two apertures330, 332 that provide an electrical connection between the heatingelement 326 and the heating terminals 320, 321. The liquid transportelement 324 can include a further aperture 334 through which a secondaryliquid transport element 340 can extend. In this manner, liquid can betransported from the reservoir 312 to the secondary liquid transportelement 340 and then to the microtextured surface of the liquidtransport element 324 for hemi-wicking across the surface into a heatingzone in proximity to the heating element 326. Although not shown in thisembodiment, the liquid transport element 324 could include furtherapertures, grooves, or notches in order to enhance airflow past theliquid transport element. In addition, although the liquid transportelement 324 is shown as positioned with its planar surface approximatelyperpendicular to the longitudinal axis of the cartridge 300, otherorientations are possible including an orientation wherein the liquidtransport element is positioned with its planar surface approximatelyparallel to the longitudinal axis of the cartridge.

The secondary liquid transport element 340 particularly can be a wickthat utilizes capillary action in the transport of liquids. A wick foruse according to the invention thus can be any material that providessufficient wicking action to transport one or more components of theaerosol precursor composition to the aerosolization zone. Non-limitingexamples include natural and synthetic fibers, such as cotton,cellulose, polyesters, polyamides, polylactic acids, glass fibers,combinations thereof, and the like. Other exemplary materials that canbe used in wicks include metals, ceramics, and carbonized materials(e.g., a foam or monolith formed of a carbonaceous material that hasundergone calcining to drive off non-carbon components of the material).Wicks further can be coated with materials that alter the capillaryaction of the fibers, and the fibers used in forming wicks can havespecific cross-sectional shape and can be grooved so as to alter thecapillary action of the fibers. For example, temperature adaptivepolymers can be used. Such adaptive polymers can be coated on fibers orused in other manners, and these polymers are effective for providingaltered liquid transport characteristics based on the surroundingconditions. Temperature adaptive polymers particularly can exhibit lowtransport at reduced temperatures and can exhibit increased transport atincreased temperatures. One example is a material known as Adaptive byHeiQ®. Fibers used in forming wicks can be provided singly, bundled, asa woven fabric (including meshes and braids), or as a non-woven fabric.Porosity of the wick material also can be controlled to alter thecapillary action of the wick, including controlling average pore sizeand total porosity. Separate wicks also can have different lengths. Theterm “wick” is also intended to encompass capillary tubes, and anycombination of elements providing the desired capillary action can beused.

The cartridge may additionally include a base shipping plug engaged withthe base and/or a mouthpiece shipping plug engaged with the mouthpiecein order to protect the base and the mouthpiece and prevent entry ofcontaminants therein prior to use as disclosed, for example, in U.S.Pat. No. 9,220,302 to DePiano et al., which is incorporated herein byreference in its entirety.

The base 302 may be coupled to a first end of the outer body 314 and themouthpiece 316 may be coupled to an opposing second end of the outerbody to substantially or fully enclose other components of the cartridge300 therein. For example, the control component terminal 304, theelectronic control component 306, the flow director 308, the atomizer310, and the reservoir 312 may be substantially or entirely retainedwithin the outer body 314. The label 318 may at least partially surroundthe outer body 314, and optionally the base 302, and include informationsuch as a product identifier thereon. The base 302 may be configured toengage the coupler 202 of the control body 200 (see, e.g., FIG. 2). Insome embodiments the base 302 may comprise anti-rotation features thatsubstantially prevent relative rotation between the cartridge and thecontrol body as disclosed in U.S. Pat. App. Pub. No. 2014/0261495 toNovak et al., which is incorporated herein by reference in its entirety.

The reservoir 312 may be configured to hold an aerosol precursorcomposition. Representative types of aerosol precursor components andformulations are also set forth and characterized in U.S. Pat. No.7,726,320 to Robinson et al., U.S. Pat. No. 8,881,737 to Collett et al.,and U.S. Pat. No. 9,254,002 to Chong et al.; and U.S. Pat. Pub. Nos.2013/0008457 to Zheng et al.; 2015/0020823 to Lipowicz et al.; and2015/0020830 to Koller, as well as WO 2014/182736 to Bowen et al, thedisclosures of which are incorporated herein by reference. Other aerosolprecursors that may be employed include the aerosol precursors that havebeen incorporated in the VUSE® product by R. J. Reynolds Vapor Company,the BLU product by Lorillard Technologies, the MISTIC MENTHOL product byMistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirableare the so-called “smoke juices” for electronic cigarettes that havebeen available from Johnson Creek Enterprises LLC. Embodiments ofeffervescent materials can be used with the aerosol precursor, and aredescribed, by way of example, in U.S. Pat. App. Pub. No. 2012/0055494 toHunt et al., which is incorporated herein by reference. Further, the useof effervescent materials is described, for example, in U.S. Pat. No.4,639,368 to Niazi et al.; U.S. Pat. No. 5,178,878 to Wehling et al.;U.S. Pat. No. 5,223,264 to Wehling et al.; U.S. Pat. No. 6,974,590 toPather et al.; U.S. Pat. No. 7,381,667 to Bergquist et al.; U.S. Pat.No. 8,424,541 to Crawford et al; and U.S. Pat. No. 8,627,828 toStrickland et al.; as well as US Pat. Pub. Nos. 2010/0018539 to Brinkleyet al. and 2010/0170522 to Sun et al.; and PCT WO 97/06786 to Johnson etal., all of which are incorporated by reference herein. Additionaldescription with respect to embodiments of aerosol precursorcompositions, including description of tobacco or components derivedfrom tobacco included therein, is provided in U.S. patent applicationSer. Nos. 15/216,582 and 15/216,590, each filed Jul. 21, 2016 and eachto Davis et al., which are incorporated herein by reference in theirentireties. In certain embodiments, the aerosol precursor compositioncan include components such as polyhydric alcohols (e.g., glycerin,propylene glycol, and mixtures thereof), water, nicotinic compounds(e.g., highly purified tobacco-derived nicotine), acids or bases,flavorants, and mixtures thereof.

The reservoir 312 may comprise a plurality of layers of nonwoven fibersformed into the shape of a tube encircling the interior of the outerbody 314 of the cartridge 300. Thus, liquid components, for example, canbe sorptively retained by the reservoir 312. The reservoir 312 is influid connection with the liquid transport element 324 using thesecondary liquid transport element 340 as an intervening conduit. Thus,the liquid transport element 324 may be configured to transport liquidfrom the reservoir 312 to the heating element 326 via a hemi-wickingliquid transport mechanism.

Additional representative heating elements and materials for use thereinare described in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. Pat. No. 8,881,737 toCollett et al., which is incorporated herein by reference, as notedabove.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Microheaters and atomizersincorporating microheaters suitable for use in the presently discloseddevices are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety.

The first heating terminal 320 and the second heating terminal 321(e.g., negative and positive heating terminals) are configured to engageopposing ends of the heating element 326 and to form an electricalconnection with the control body 200 (see, e.g., FIG. 2) when thecartridge 300 is connected thereto. Further, when the control body 200is coupled to the cartridge 300, the electronic control component 306may form an electrical connection with the control body through thecontrol component terminal 304. The control body 200 may thus employ theelectronic control component 212 (see, FIG. 2) to determine whether thecartridge 300 is genuine and/or perform other functions. Further,various examples of electronic control components and functionsperformed thereby are described in U.S. Pat. App. Pub. No. 2014/0096781to Sears et al., which is incorporated herein by reference in itsentirety.

During use, a user may draw on the mouthpiece 316 of the cartridge 300of the aerosol delivery device 100 (see, FIG. 1). This may pull airthrough an opening in the control body 200 (see, e.g., FIG. 2) or in thecartridge 300. For example, in one embodiment an opening may be definedbetween the coupler 202 and the outer body 204 of the control body 200(see, e.g., FIG. 2), as described in U.S. Pat. No. 9,220,302 to DePianoet al., which is incorporated herein by reference in its entirety.However, the flow of air may be received through other parts of theaerosol delivery device 100 in other embodiments. As noted above, insome embodiments the cartridge 300 may include the flow director 308.The flow director 308 may be configured to direct the flow of airreceived from the control body 200 to the heating element 326 of theatomizer 310.

A sensor in the aerosol delivery device 100 (e.g., the flow sensor 210in the control body 200; see, FIG. 2) may sense the puff. When the puffis sensed, the control body 200 may direct current to the heatingelement 326 through a circuit including the first heating terminal 320and the second heating terminal 321. Accordingly, the heating element326 may vaporize the aerosol precursor composition directed to anaerosolization or heating zone from the reservoir 312 by the liquidtransport element 324. Thus, the mouthpiece 326 may allow passage of airand entrained vapor (i.e., the components of the aerosol precursorcomposition in an inhalable form) from the cartridge 300 to a consumerdrawing thereon.

Various other details with respect to the components that may beincluded in the cartridge 300 are provided, for example, in U.S. Pat.App. Pub. No. 2014/0261495 to DePiano et al., which is incorporatedherein by reference in its entirety. Additional components that may beincluded in the cartridge 300 and details relating thereto are provided,for example, in U.S. Pat. Pub. No. 2015/0335071 to Brinkley et al.,filed May 23, 2014, which is incorporated herein by reference in itsentirety.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

In another embodiment substantially the entirety of the cartridge may beformed from one or more carbon materials, which may provide advantagesin terms of biodegradability and absence of wires. In this regard, theheating element may comprise carbon foam, the reservoir may comprisecarbonized fabric, and graphite may be employed to form an electricalconnection with the power source and control component. An exampleembodiment of a carbon-based cartridge is provided in U.S. Pat. App.Pub. No. 2013/0255702 to Griffith et al., which is incorporated hereinby reference in its entirety.

FIG. 4 illustrates a top view of another embodiment of an atomizer 310that could be used in an aerosol delivery device of the invention. Asshown, the atomizer 310 includes a liquid transport element 324 with amicrotextured surface upon which a heating element 326 is patterned(e.g., as a conductive ink film).

The heating element 326 extends from a first aperture 330 to a secondaperture 332, which serve as points of electrical connection for theheating element. Each aperture provides a space for forming anelectrical connection between the heating element 326 and heatingterminals (not shown) such as terminals 320, 321 shown in FIG. 3. Ifdesired, a fastener (not shown) formed of a conductive material (e.g., ametal screw) could be inserted in each aperture in order to form part ofthe electric connection with the heating element 326 and also provide afastening function for connecting the atomizer 310 to another componentof an aerosol delivery device. As shown, each aperture 330, 332 caninclude an optional conductive coating or film 350 around the peripheryof the aperture and extending through at least a portion of the depth ofthe aperture (and advantageously for the entire depth thereof). Thepresence of the conductive coating or film, which can be constructed ofthe same conductive material as the heating element 326, can improveelectrical connectivity with the heating element. Note that rather thanprovide apertures in order to provide electrical connectivity to theheating element 326, electrical connections could be made by connectingthe heating element to terminals placed above the microtextured surface,thereby avoiding the need for apertures.

FIG. 5 illustrates a top view of another embodiment of the atomizer 310similar to FIG. 4 discussed above. However, as illustrated, the heatingelement 326 is configured in a different pattern such that multipleheating element portions are patterned on the liquid transport element324 to increase the heating across the surface. The number of heatingelement portions can vary and will typically include from one to tenheating element portions of varying shape and in varying patterns acrossthe surface, depending on the desired size and shape of the heatingzone. Note that the multiple heating element portions can extend fromshared apertures as shown or each heating element portion can extendbetween separate apertures to form completely separate heating elementsthat can be controlled separately.

FIG. 6 illustrates the top view of yet another embodiment of an atomizer310 of the invention. As noted previously, the precise shape of theatomizer 310 can vary, with circular shapes as shown in FIGS. 4 and 5being one example, and the rectangular shape of FIG. 6 representinganother example. Similar to FIG. 4, the atomizer 310 of FIG. 6 includesa heating element 326 (e.g., a conductive ink film) patterned on aliquid transport element 324 having a microtextured surface. The heatingelement 326 can extend between two apertures 330, 332 that provide ameans for electrical connection of the heating element. Similar to FIG.3, the atomizer 310 of FIG. 6 also includes two apertures 334 throughwhich a secondary fluid transport element (e.g., a fibrous wick), notshown, can pass in order to achieve fluid connection between themicrotextured surface and the secondary fluid transport element. Inother embodiments, apertures for a secondary fluid transport elementcould be avoided by positioning the ends of the secondary fluidtransport element, which are typically adapted for fluid communicationwith a reservoir, in a different location, such as overlying themicrotextured surface.

The atomizer of the invention can comprise a protective layer overlyingthe microtextured surface of at least a portion of the liquid transportelement. A protective layer can be advantageously used to prevent directcontact between an aerosol precursor composition and the heating elementand thereby passivate the heating zone of the atomizer. The protectivelayer can also serve as a barrier to prevent direct contact between theheating element and any secondary fluid transport element present in thedevice. The protective layer is typically formed of a material that istemperature stable under the operating temperatures for the atomizer andcan be heat radiant and/or heat conductive. For example, the protectivelayer can be temperature stable at a temperature of about 150° C. orgreater, about 200° C. or greater, about 300° C. or greater, about 400°C. or greater, or about 500° C. or greater. In other embodiments, theprotective layer can be temperature stable in a temperature range ofabout 125° C. to about 750° C., about 150° C. to about to about 650° C.,or about 175° C. to about 500° C.

The protective layer can be in direct contact with an aerosol precursorcomposition or component thereof. Accordingly, it is preferable for theprotective layer to be substantially chemically non-reactive with thevarious compounds that may be included in the aerosol precursormaterial. By substantially chemically non-reactive is meant that anychemical reaction between the protective layer and a component of theaerosol precursor material is sufficiently limited such that theprotective layer is not breached so as to allow the aerosol precursorcomposition to be in direct contact with the electrically conductivelayer of the heating element. Alternately, the phrase can mean that anychemical reaction between the protective layer and a component of theaerosol precursor material is sufficiently limited such that chemicalcompounds present in the protective layer are not released (or newchemical compounds formed) so as to combine with the formed aerosol forinhalation by a consumer.

In certain embodiments, the protective layer can comprise asilicon-based material, such as silicon dioxide, silicon nitride orsilicon carbide. Alternatively, the protective layer can be formed of ametal oxide material such as alumina. The thickness of the protectivelayer can vary, with exemplary thicknesses including about 0.1 micron toabout 1.0 micron. Any coating method known in the art could be used toapply the protective layer, including plasma-enhanced chemical vapordeposition (PECVD).

FIG. 7 provides a side view of an atomizer 310 showing a protectivelayer 360 applied to the microtextured surface of a liquid transportelement 324. Note that the protective layer 360 can be applied to all oronly a portion of the microtextured surface. For example, the protectivelayer 360 could be applied to only an area encompassing the heatingelement (see, FIGS. 4-6) to prevent contact between the heating elementand an aerosol precursor composition.

FIG. 8A provides a perspective view of another embodiment of a cartridge300′ that includes a mouthpiece 316′, an outer body 314′, and heatingterminals 320′ and 321′, which function equivalently as described inconnection with FIG. 3. As shown in the exploded view of FIG. 8B, thecartridge 300′ can further include a flow tube 362 adapted to channelaerosol from the atomizer 310′ to the mouthpiece 316′. An aerosolprecursor composition (not shown) can be housed in the reservoir spacebetween the outer body 314′ and the outer walls of the tube formed byflow tube 362. The heating terminals 320′ and 321′ provide an electricconnection to the atomizer 310′, which includes a liquid transportelement 324′ with a microtextured surface, a heating element 326′ (e.g.,a patterned conductive film), and two apertures 330′ and 332′. Thecartridge 300′ further includes a base plate 364. As shown, unlike theembodiment of FIG. 3, the cartridge 300′ includes a disc-shapedsecondary fluid transport element 340′ overlying the periphery of themicrotextured surface of the liquid transport element 324′. Thesecondary fluid transport element 340′, which could be constructed ofany of the wicking materials noted herein, provides a fluid connectionbetween the reservoir containing aerosol precursor material and themicrotextured surface of the liquid transport element 324′.

FIGS. 9-11 illustrate a still further embodiment of a cartridge of thepresent disclosure. As shown in FIG. 9, the cartridge 370 can include amouthpiece 372 and an outer reservoir 374. An atomizer 376 is locatedcentrally relative to the reservoir 374. As shown in the cross-sectionalviews of FIGS. 10 and 11, a flow tube 378 provide a path for aerosol totravel from the atomizer 376 to the mouthpiece 372 and a second flowtube 379 that brings air drawn through the device to the atomizer.

Referring to FIGS. 10 and 11, the atomizer 376 includes a liquidtransport element 380 with a microtextured surface having anelectrically conductive film heating element 382 patterned thereon. Theatomizer 376 also includes two longitudinally-extending secondary liquidtransport elements 386 (e.g., a fibrous wick or any other wickingmaterial noted herein) that pass through two sets of apertures such thatthe secondary liquid transport element is in fluid communication withthe microtextured surface. The opposing ends 390, 392 of eachlongitudinally-extending secondary liquid transport element 386 extendinto the reservoir 374 and thereby provide a fluid pathway for aerosolprecursor composition from the reservoir to the microtextured surface.Screws 396 formed of a conductive material hold the atomizer in 376 inplace and form part of the electric connection between the heatingelement 382 and heating terminals 398, 399.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1. An aerosol delivery device, comprising: a reservoir containing aliquid aerosol precursor composition; an atomizer comprising anelectrical resistance heating element and a nonfibrous liquid transportelement having a microtextured surface adapted for surface wicking ofthe liquid aerosol precursor composition across the microtexturedsurface, the microtextured surface of the liquid transport element beingin fluid communication with the reservoir and in fluid communicationwith the electric resistance heating element.
 2. The aerosol deliverydevice of claim 1, wherein the electrical resistance heating element isa film patterned on the microtextured surface of the nonfibrous liquidtransport element.
 3. The aerosol delivery device of claim 2, whereinthe electrical resistance heating element is in the form of a conductiveink patterned on the microtextured surface.
 4. The aerosol deliverydevice of claim 2, wherein the nonfibrous liquid transport element isplate-shaped.
 5. The aerosol delivery device of claim 2, wherein thefilm patterned on the microtextured surface extends from a first end toa second end, further comprising an aperture in the nonfibrous liquidtransport element proximal to each of the first end and the second end,and further comprising a positive electric terminal engaged with a firstend of the film through an aperture and a negative electric terminalengaged with a second end of the film through an aperture such that anelectric current can be passed from terminal to terminal.
 6. The aerosoldelivery device of claim 2, further comprising a secondary liquidtransport element interposed in a flow path between the reservoir andthe nonfibrous liquid transport element and wherein the secondary liquidtransport element is in fluid communication with the reservoir and influid communication with at least a portion of the nonfibrous liquidtransport element.
 7. The aerosol delivery device of claim 6, whereinthe microtextured surface of the nonfibrous liquid transport elementcomprises a heating zone that includes the electrical resistance heatingelement and a second zone in spaced relation from the electricalresistance heating element, and wherein the secondary liquid transportelement is in fluid communication with at least a portion of the secondzone such that a flow path for the liquid aerosol precursor compositionis established from the secondary liquid transport element to the secondzone and from the second zone to the heating zone across themicrotextured surface.
 8. The aerosol delivery device of claim 7,wherein the nonfibrous liquid transport element is plate-shaped with aperipheral edge surrounding a central region, and wherein the secondzone is located proximal to the peripheral edge and the heating zonecomprises at least a portion of the central region.
 9. The aerosoldelivery device of claim 6, wherein the secondary liquid transportelement comprises a fibrous material or ceramic material.
 10. Theaerosol delivery device of claim 6, wherein the secondary liquidtransport element is overlying at least a portion of the microtexturedsurface.
 11. The aerosol delivery device of claim 10, further comprisingat least one aperture through the nonfibrous liquid transport element,wherein at least a portion of the secondary liquid transport elementpasses through the at least one aperture.
 12. The aerosol deliverydevice of claim 2, wherein the film patterned on the microtexturedsurface comprises one or more straight or curvilinear elements extendingfrom a first end to a second end.
 13. The aerosol delivery device ofclaim 2, further comprising a protective layer overlying the electricalresistance heating element such that liquid aerosol precursorcomposition transported across the microtextured surface does notdirectly contact the electrical resistance heating element.
 14. Theaerosol delivery device of claim 1, wherein the reservoir and atomizerare housed in a cartridge adapted for attachment to a control body, thecontrol body comprising an electrical power source configured to provideelectrical current flow to the electrical resistance heating element.15. The aerosol delivery device of claim 1, further comprising one ormore of: (a) an electrical power source configured to provide electricalcurrent flow to the electrical resistance heating element; (b) acontroller adapted for controlling electrical current flow from theelectrical power source; and (c) a flow sensor in communication with thecontroller and adapted to sense a pressure drop within the aerosoldelivery device or a portion thereof.
 16. An aerosol delivery device,comprising: a reservoir containing a liquid aerosol precursorcomposition; an atomizer comprising a nonfibrous liquid transportelement having a microtextured surface adapted for surface wicking ofthe liquid aerosol precursor composition across the microtexturedsurface and an electrical resistance heating element in the form of afilm patterned on the microtextured surface of the nonfibrous liquidtransport element, the film having a first end and a second end, themicrotextured surface of the liquid transport element being in fluidcommunication with the reservoir and in fluid communication with theelectrical resistance heating element; and an aperture in the nonfibrousliquid transport element proximal to each of the first end and thesecond end, and further comprising a positive electric terminal engagedwith a first end of the film through an aperture and a negative electricterminal engaged with a second end of the film through an aperture suchthat an electric current can be passed from terminal to terminal. 17.The aerosol delivery device of claim 16, wherein the nonfibrous liquidtransport element is plate-shaped.
 18. The aerosol delivery device ofclaim 16, further comprising a secondary liquid transport elementinterposed in a flow path between the reservoir and the nonfibrousliquid transport element and wherein the secondary liquid transportelement is in fluid communication with the reservoir and in fluidcommunication with at least a portion of the nonfibrous liquid transportelement.
 19. The aerosol delivery device of claim 18, wherein themicrotextured surface of the nonfibrous liquid transport elementcomprises a heating zone that includes the electrical resistance heatingelement and a second zone in spaced relation from the electricalresistance heating element, and wherein the secondary liquid transportelement is in fluid communication with at least a portion of the secondzone such that a flow path for the liquid aerosol precursor compositionis established from the secondary liquid transport element to the secondzone and from the second zone to the heating zone across themicrotextured surface.
 20. The aerosol delivery device of claim 19,wherein the nonfibrous liquid transport element is plate-shaped with aperipheral edge surrounding a central region, and wherein the secondzone is located proximal to the peripheral edge and the heating zonecomprises at least a portion of the central region.
 21. The aerosoldelivery device of claim 18, wherein the secondary liquid transportelement comprises a fibrous material or ceramic material.
 22. Theaerosol delivery device of claim 18, wherein the secondary liquidtransport element is overlying at least a portion of the microtexturedsurface.
 23. The aerosol delivery device of claim 22, further comprisingat least one aperture through the nonfibrous liquid transport element,wherein at least a portion of the secondary liquid transport elementpasses through the at least one aperture.
 24. The aerosol deliverydevice of claim 16, wherein the film patterned on the microtexturedsurface comprises one or more straight or curvilinear elements extendingfrom the first end to the second end.
 25. The aerosol delivery device ofclaim 16, further comprising a protective layer overlying the electricalresistance heating element such that liquid aerosol precursorcomposition transported across the microtextured surface does notdirectly contact the electrical resistance heating element.